Wrench Head Forming via Concurrent Press-Forging and Squeezing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for forming a wrench are inefficient due to complex steps and the need for multiple presses, leading to prolonged processing time and increased costs.
Innovation Solution
A method involving preparing a flat blank, initially press-forging to form a wrench-shaped part and hole, bending the head to create curved and stretched sections, and using a gripping apparatus to shape the interior structure by applying a squeezing force with a punch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cold forging method with multiple presses is used, then the wrench can be formed with separate steps for head forming, stamping, and residual material removal, but the processing time is prolonged and processing efficiency is reduced
Solution Approach 1:
The patent combines multiple separate operations (head forming, stamping, and residual material removal) into a single integrated die set. The die includes a punch with a wrench-shaped part forming section and a hole forming section, allowing concurrent formation of both features in one pressing operation, eliminating the need for multiple presses and sequential steps
Solution Approach 2:
The die is segmented into functional sections: the punch is divided into a wrench-shaped part forming section and a hole forming section, while the die cavity includes a curved section forming portion and a stretched section forming portion. This segmentation allows each section to perform its specific function simultaneously during a single pressing operation
2Device complexity
If traditional method forms two round heads first and then presses with punch, then the processing steps become complex and multiple presses are required, but the interior structure density is adequate
Solution Approach 1:
The patent combines wrench-shaped part forming and hole forming into a single integrated die operation. The punch simultaneously forms both the wrench-shaped part and the hole in one pressing action, eliminating the need for separate pressing operations and reducing device complexity
Solution Approach 2:
The patent applies squeezing force to the curved section and stretched section during the pressing operation, which changes the density parameter of the interior structure. This squeezing action compacts the metal flow and creates a denser interior structure in the formed features
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces processing time, increases efficiency, and enhances the quality of the wrench by concurrently shaping the wrench part and hole, resulting in a denser interior structure and improved product quality.
Implementation Method 1
using a punch to press the hole of the head, thereby squeezing the curved section and the stretched section enclosed by the gripping apparatus gradually when the punch presses the hole to provide a denser interior structure for the sections
Implementation Method 2
bending the head so that the head can be inclined to the shank and form a curved section and a stretched section bent by different angles at two opposite side surfaces where the head and the shank are joined
Data Source
AI summary
A method for forming a wrench end includes the steps of preparing a flat blank, initially press-forging at least one end of the blank to form a head with a wrench-shaped part and a hole on the blank, bending the head to form a curved section and a stretched section which are bent at different angles, and shaping the head by holding the curved section and the stretched section with a gripping apparatus and then pressing the hole of the head with a punch in order to subject the two sections to a squeezing force whereby the sections can have a denser interior structure and facilitate a final shaping of the head. The method facilitates a quick shaping of the wrench end and increases the efficiency of forming a wrench product.